Wall panel



WALL PANEL 5 Sheets-Sheet 1 Filed Aug. 5, 1955 that N M Y R m w W M N D R E w W H T I A m E 6 w 3 R 2 7 3 M a n M m MW 9 W F 2 I n I R. l lm 6 n 5 w a. a 6 m 2 6 H 7,

y 23, 1961 R. L. HILDEBRAN 2,985,262

WALL PANEL Filed Aug. 5, 1955 s Shets-Sheet 2 INVENTOR.

ROBERT L. HILDEBRAN NW A.

ATTORNEY y 23, 1961 R. HILDEBRAN 2,985,262

WALL PANEL Filed Aug. 3, 1955 5 Sheets-Sheet 3 INVENTOR. ROBERT L. HILDEBRAN ATTOR N EY WALL PANEL Robert L. Hiidebran, White Plains, N.Y., assignor to United States Plywood Corporation, New York, N.Y., a corporation of New York Filed Aug. 3, 1955, Ser. No. 526,290

Claims. (Cl. 189-34) This invention pertains to a panel adapted for forming the outside surface of a building, either as the structural member itself as in a low building, or to be hung between columns and beams as in curtain wall construction.

Another object is to form a panel having a clean, decorative face which is common today in modern construction, the face being made of aluminum, stainless steel, porcelainized metal, embossed metal or other decorative face.

Another object of my invention is to provide metalfaced panels, having a honeycomb core, which are vented to the atmosphere for breathing purposes whereby internal pressure built up by changes in temperature will be relieved.

A further object of my invention is to provide a vented building panel in which an accumulation of moisture normal-1y will be prevented, but if any accumulation does occur, the water droplets can drain to the outside thereby preventing an excess of moisture within the panel and thereby avoiding deterioration and delamination.

A still further object is to provide a panel which eliminates the former pan construction of the faces and by reason of the extended edges of the plain flat faces can be cut readily so that the tolerance in making the panels prior to setting them in the previously formed framework of the building does not have to be kept within close limits.

Another object is to eliminate a metal-to-metal contact between the inner and outer faces of the panel.

Other objectives will be apparent from a reading of the following description and claims.

With the foregoing and other objects in view as will appear from a reading of the following specification and claims, the invention resides in the novel arrangement and combination of parts and in the details of construction and process of installation hereinafter described and claimed, it being understood that changes in the precise embodiment of the invention may be made within the scope of what is claimed without departing from the spirit of the invention. It will be further understood that my invention is susceptible of embodiment in many and various forms, some of which are illustrated in the. accompanying drawings, and that the structural details and particular steps of the method herein set forth may be varied to suit particular purposes and still remain within my inventive concept.

Referring to the figures;

Fig. 1 shows the general environment of the panel in the framework of a structure such as in a large, multistoried building. I

Fig. 2 is a cross-sectional view taken on the line 29-2 of Fig. 1.

Fig. 3 is a cross-sectional view taken on the line 33 of Fig. 1.

Fig. 3a is a view similar to Fig. 3 but showing a shim 14 of substantial dimensions at spaced intervals being used to support the panel instead of hat-shaped ing member 17. V

supportout from either side.

"2,985,262 Patented May 23, 1961 Fig. 4 is a modified isometric and enlarged view wherein a different type framing system is used, i.e., difierent type frame members and different type positioning stops.

Fig. 5 is a further modified view showing two panels arranged Within a single opening in the framework. In this construction, a different type head structure is provided at the top of the lower panel.

In Fig. 1, 1 indicates the framing or framework of a building into which panel 2 is positioned. Panel 2 comprises a honeycomb core or other type of grid core 3 and two faces 4 and 5.

The framework 1 may comprise two elements, such as, a U-shaped member 6, and an interfitting member 7, or may be in the shape of a boxlike structure 8 as shown in the modification of Fig. 4, or may be in various other shapes. Panel 2 is closed around three of its sides by a U-shaped channel 9. On the lower side of the panel, this U-shaped member 10 is provided with venting and drainage apertures 11, as shown in Figs. 4 and 5.

The preferred form of my invention is to join the foregoing channel members into a tight frame. This may be done by Welding, brazing, or mechanically joining the members together. However, the various channel members may be individually positioned and later joined together after the panel has been assembled and cured. It is, of course, desirable that the joint at the corners be water-tight.

In assembling the panel 2, the channel frame assembly or the individual members 9-10 are positioned between the faces 4 and 5 by means of spacer blocks or shims 13. The channel members are sealed in this space by a heavy dark mastic 12 which is non-conductive of heat, is non toxic and is resistant to water, weather, non-oxidizing acids and diluted alkalies. The type mastic which'is used is very important, since it must have excellent temperature adaptability to withstand not only the movement of the metal components during normal weather conditions, but also during the fabricating process. It has been found that Igas, a black non-meltable mastic, manufactured from refined asphalts, resins and plasticizing compounds reinforced with long fibered asbestos, is particularly suitable as a panel sealant.

In positioning the frame assembly or the channel members within the extending faces 4 and 5, spacers or shims 13 are used in order to place the channel equidistant from both faces and to prevent the mastic from being squeezed Almost any type or dimension of shim structure can be used. For example, the shims can be in the form of round knobs having a diameter of from A to A" and a thickness of approximately like dimensions. These shims are spaced along the length of V, the panel and generally two or three on each side are suflicient. The dimensions of shims are subject to considerable variation.

The faces are bonded to the core normally under low pressure of the order of 1 to 5 pounds per square inch. Dependingupon the particular adhesive used to and flexible seal must be used for optimum results. This sealing compound should be a non-oxidizing, non-staining and non-toxic compound with good adhesion'to building materials, such as aluminum, steel, porcelain enamel,

, etc, and must be softer than the panel mastic 121e,

- 3 insure that best sealing in the framing. I have found that Weldflex, otherwise known as Parflex #14 (indicated by numeral 23), a mixture of polyisobutylene, asbestos fibers and certain mineral fillersand'titanium dioxide, is particularly suitable as a panel-to=frarne sealant. 'This sealant 23 may be in the shape of individual ribbons as shown in Fig. 4, or may be-packed to fill theentire area as shown in Fig. 5. Here again shirns 13 are used to maintain a fixed distance between the faces of the panel and the stops.

As shown in'Fig. 3a, two or three supportingblocks or shims 14 may be spaced along the length of the panel to raise the panel above the supporting framework and permit the panel to breathe without restraint. These shims may be small, for example, A." x /2"x 2'' in size, and-may be made of hardwood, tempered hardboard, high pressure plastic laminate, etc. These supporting shims are made of the same material as shims 13, but obviously perform an entirely different function and therefore must be of considerable larger size. However, due to the danger that in a heavy rainstorm water may be blown beneath the outer edge of the panel and through the vents 11 into the panel, in my preferred construction, illustrated in Fig. 3, I use a combination supporting and covering or shielding member 17 and thereby 'dispense with supporting shims 14.

Referring to Figs. 3 and 4, there is provided a hatshaped supporting member contacting the lower U-shaped channel member '10. The purpose of the supporting member is to shield or protect the venting apertures against any possible ingress of moisture even during hurricanes orother unseasonable weather conditions, and also tov support the panel a fixed distance from the sill or frame member 6. The interior of the panel is at all times free to breathe through the vent 11 and support 17 to theoutside atmosphere. There is thus provided a circuitous passage since the support 17 extends past the bottom horizontal channel member but stops short of the frame elements '1 and 8 (note Figs. 2, and 4, re spectively) whereby an unobstructed passage is provided at the bottom of the panel at the two vertical edges thereof (note Fig. 3).

In certain construction, it is desirable to insert two panels between the framework 1. A construction of this type is shown in Fig. 5, wherein the lower-panel 18 has the upper edge of its faces 19 and 20 bent inwardly to form a seat 21 and 22 for the upper panel 2. In this particular construction, there is no need for shims within the sealing compound23 since the rigid supports 17 provide the predetermined spacing distance between the seat formed in the lower panel and the edges of the upper panel. tioned by means of stop members 24 similar to the mem ber illustrated in Fig. 4. Obviously, three or more panels arranged in a vertical direction could be provided.

It is thus seen that Ihave provided a new construction which while open to the outdoor atmosphere and permitting breathing during periods that excessive temperature develops within the panel, nevertheless, prevents rain from being blown up into the panel.

A very important feature of my invention is that the tolerance between the frame members providing the openings for the panel may vary within comparatively wide limits, thereby providing. flexibility for installation. a In other words, if the panels Zwill not fit normally within theframework 1 of the structure, the U-shaped channels 9 and 10, together with the ends of the faces, may be cut off on one side, or on three or four sides if necessary, and the width, height, or both, of the panels substantially reduced. This cutting of the edges of the panel 7 will not affect the efficiency of thepanel, since as long as the channel members 9 have a slight overhanging or extending edge which is-satisfactorily sealed and shimmed,

asaaasa a The upper edge of the upper panel can be posicreased use of porcelain enamelled, aluminum, and stainless steel faces on buildings, this invention has been a substantial contribution to the art, and particularly over the former pan type construction wherein both the pan type panels and the frame openings had to be held within close tolerances.

The major advantages obtained by my improved construction may be summarized as follows:

(1) Flexibility for installation as mentioned in the preceding paragraph.

(2) Maximum insulation qualities, i.e., metal-to-metal contact, which provides heat conductance, is eliminated.

(3) Dry interior of panel, i.e., sealed edges, exclude entrance of water which causes deterioration of bond and delamination between faces and core.

(4) Downspout provided by channels, i.e., if the panel is not sealed properly and leakage occurs between the framing andthe panels, or in other joints in the wall structure, a gutter is provided 'by the upper channel member and a downspout elfect by the side channel members.

(5) Ease of manufacturing panels, i.e., no special assembly tools, special press, or fixtures required.

(6) Clean-up of pressed panel eliminated, i.e., the edge sealant acts to preventthe flashing out of the face core bonding adhesive making final clean-up after pressing. the panel unnecessary.

(7) Ease of carrying inventory, i.e., plain faces (as compared with former pan type construction) may be carried in stock as porcelain enamel aluminum and'steel, and alumilited aluminum.

(8) Standard sheet sizes utilized, i.e., plain skins make possible maximum utilizationof standard commercial sheet widths. In the past, panel dimensions with skins of pan construction have on occasion necessitated sheets of extra width which are difficult to obtain and more expensive. 7

(9) Minimum cost, i.e., uses simplified, standard type face, and standard rolled channel sections for edging.

The use of a flexible edge sealant compound between the channels and the faces permits ordinary commercial to1er ances for the channels to be acceptable since the give in the sealant at the necessary point overcomes variation in thechannel width measured across the legs.

(10) Ease of shipping, i.e., plain faces are less susceptible to damage both when shipped as unassembled faces and also after assembly.

.(11) Less susceptible to damage, i.e., as a rule, faces of pan construction are not flat, hence in the laminating process of making the panel, these distorted pans are forced into a flat .condition developing stress'concentrations which frequently result in the enamel coat fracturing. from the base metal. 7

While I haveillustrated and described my invention particularly with a honeycomb core, it could also be used in other types of cores, i.e., plywood, low density rigid plastics, etc. Also, while my preferred .form of channel members and hat shaped supporting member is made of steel, aluminum or other metals, any structural materials. which accomplish the aforesaid purposes may be use What is claimed is:

l. A curtain wall panel comprising a low density core material, apair of air impervious faces secured to said core material, and a U-shaped channel member having elongated leg portions positioned on at least oneedge of said panel and wholly within the length and widthof said panel, said low density core being a reticulated web, the air impervious faces being made of metal, and the U-shaped channel members encircling the panel on all four edges,.one of said channel members having atleast oneaperture therein whereby the interior of the panel maybreathe'i'upon differential changes in temperature between theinterior of the panel and theambientoutsideztemperature and-excessive interior panel pressures are avoided, sealing compound positioned between-each of said faces and said U-shaped channel member, and shims embedded in said sealing compound to center said U-shaped channel member equidistant between said faces.

2. A curtain wall panel as set forth in claim 1, a support therefor, and means provided whereby the lower edge of the panel is elevated above said support.

3. A curtain wall panel as set forth in claim 2 in which said means comprise a shim placed beneath the lower edge of said panel.

4. A curtain wall construction as set forth in claim 2 in which said means comprise a hat-shaped supporting member positioned almost wholly within the U-shaped channel member and extending slightly beyond the area of the U-shaped member in the direction of the height of the hat section proper.

5. A curtain wall panel as set forth in claim 4 in which the hat shaped supporting member is longer than said U-shaped channel member and therefore extends beyond the confines of the U-shaped channel member in a horizontal direction.

6. In a steel structure involving horizontal and vertical framing members, a curtain wall panel having U-shaped channel members encircling the panel member, one of said U-shaped channel members having an aperture therein so that excessive interior pressure in the panel may be freely relieved to the outside atmosphere, a hat-shaped supporting member positioned almost wholly within the U-shaped member, said hat-shaped member having substantially vertical walls spaced from the walls of the U-shaped channel member and resting on said horizontal framing member whereby the edge of said panel is elevated from the supporting structure.

7. In a steel structure involving horizontal and vertical framing members, a curtain wall panel having a core and two metal faces, U-shaped channel members encircling the panel member, one of said U-shaped channel members having an aperture therein so that excessive interior pressure in the panel may be freely relieved to the outside atmosphere, a hat-shaped supporting member positioned almost wholly within the U-shaped member, said hat-shaped member resting on said horizontal framing member whereby the edge of said panel is elevated from the supporting structure, metal stops used to position said panels between openings formed by said horizontal and vertical framing members, a mastic forming a seat between said panels and said stops, and shims embedded in said mastic to limit the movement of said panels and prevent the mastic from being forced out.

8. In a structure as set forth in claim 7 in which the edge of said metal faces and the ends of said U-shaped channel members extend beyond the area covered by said core whereby the edge and ends may be cut off on the site without damaging the panel and thereby be fitted within the horizontal and vertical framing members thus making close plant tolerance unnecessary.

9. In a structure as set forth in claim 7 in which the upper and side U-shaped channel members are solid, nonperforated sheet metal so as to provide a gutter at the top of said panel and downspouts at the sides thereof, said downspouts leading directly to the outside for any water leakage past said mastic, and said hat-shaped supporting element covers and protects the interior of the panel from water being blown thereinto while at the same time providing a circuitous passageway for air into and from the interior of the panel to the outside.

10. In a steel structure involving horizontal and vertical framing members, a curtain wall panel having U- shaped channel members encircling the panel member, one of said U-shaped channel members having an aperture therein so that excessive interior pressure in the panel may be freely relieved to the outside atmosphere, a hat-shaped supporting member positioned almost wholly within the U-shaped member, said hat-shaped member having substantially vertical walls spaced from the walls of the U-shaped channel member, and resting on said horizontal framing member whereby the edge of said panel is elevated from the supporting structure, a second hat-shaped supporting member on the upper side of said panel member, the upper end of said panel member having an inwardly extending edge forming a seat, a mastic in said seat, a second curtain wall panel member positioned in and partially embedded in said mastic in said seat, and said second wall panel member positioned a predetermined distance above the edges of said first named curtain Wall panel member by means of said cooperating hat-shaped supporting members, whereby to prevent the mastic from being forced out between said curtain wall panel members and thereby providing a moisture-proof seal between said abutting panel members.

References Cited in the file of this patent UNITED STATES PATENTS 2,054,694- Eldredge Sept. 15, 1936 2,519,160 Tucker Aug. 15, 1950 2,613,768 Gillett Oct. 14, 1952 2,622,999 Faussner Dec. 23, 1952 2,718,287 Hobart Sept. 20, 1955 2,719,809 Herts Oct. 4, 1955 2,720,948 Pajak Oct. 18, 1955 FOREIGN PATENTS 769,067 France June 5, 1934 58,919 France Dec. 2, 1953 (Addition to No. 1,010,612)

OTHER REFERENCES Sweets 1954 Catalog, sec. 16b/Tr., pp. 63-65, Truscon Metal Windows and Doors.

Sweets Catalog 1954, see. 5d/Te., pp. 4 and 6, Texlite Inc. 

